Bud Graham revisits his January/February column on problems that plague tube mills (or nearly any manufacturing company, for that matter) and shares some reader feedback. Also, he provides the runners-up and winner of a caption contest for a photo that also appeared in the January/February issue.

In any stamping process including progressive dies, transfer dies, or line dies, three factors are essential to consider when processing a piece of flat metal into a finished part: What is the metal? What is the metal's thickness? What are the part tolerances?

Although the upfront costs of installing machine safeguards can be expensive, it is far more expensive to put your company at risk for employee injury and the resulting medical expenses, lost production, fines, and lawsuits.

Under the right circumstances, hydroforming can be a viable, cost-effective manufacturing process. Tube hydroforming often produces stronger structural components than can be achieved with more conventional methods. This article explains tube hydroforming, describes its evolution, and discusses the factors that should be considered when deciding whether to use the process.

Figure 1
Part VII of this series introduced two basic types of metals used to manufacture stamped parts—ferrous, metals that contain iron, and nonferrous, metals that do not contain iron. This article discusses the specific mechanical properties of these metals in more detail.The metal's...

Determining how much a metal can deform before thinning or fracture occurs is necessary for designing a reproducible forming operation. Testing the incoming sheet material is also essential because material properties may vary from coil to coil and affect the part quality and scrap rate. Understanding a material's plastic strain ratio and how to measure it are crucial in accurately establishing a material's formability.

Senior Editor Eric Lundin visited a fabricator that specializes in aircraft components, M-DOT Aerospace, to learn how the company uses warm-forming of titanium to manufacture a cradle for an auxiliary power unit, or APU. Understanding titanium's characteristics is the key in forming this durable, corrosion-resistant, tough material.

After years of working in fabricating and machining, Shawn McFadden struck out on his own to start a fabrication shop, which later evolved into a custom motorcycle shop. He doesn’t use the latest CNC machines with digital readouts and other state-of-the-art manufacturing equipment. He uses manually controlled machines and ingenuity.

The mechanical aspects of rotary draw tube bending haven't changed since modern tooling was developed 50 years ago. Likewise, the role of the tooling (mandrel, pressure die, bend die, and wiper die) hasn't changed. However, tube fabricators these days have many choices in regard to the tooling, especially wiper dies. Choices include material, rake angle, and whether the wiper die's feathered edge is fully machined or honed by hand.

Self-piercing riviting, an alternative sheet joining method, is being used more to join aluminum sheets. The finite element method can be employed to study the SPR process and joints, perhaps even leading to the elimination of physical testing of these mechanical joints.

Ever wonder why associations exist—what purposes they serve and why people join them? This article explains just what an association is, traces the history of associations, and describes how these organizations benefit members and the general public.

Generations ago blacksmiths served long apprenticeships and acquired the knowledge to make their own tools. Today blacksmithing often is pursued by untrained hobbyists who need economical tools. This article is about a seasoned blacksmith who uses his skills to make tools and then markets them using the latest technology.

Pacific Metal Cutting of Placentia, Calif., wasn't struggling when it bought its first waterjet in May 2004. After two years of waterjet ownership and the addition of a second table, the metal cutter is struggling to keep up with new business.

Site Sponsor

CS Unitec's Surface Finisher - Linear Grinder - Model PTX Eco Smart

The PTX Eco Smart is a multi-functional grinding and polishing system for flat surfaces and open or closed pipe constructions. Grind from coarse to very fine finishes, and burnish to a high-gloss finish. Work with stainless steel, steel and nonferrous metals (aluminum, brass, bronze and copper), wood, and rigid plastic.

More Media:

TPJ - The Tube & Pipe Journal®

The only North American publication devoted to the metal tube and pipe industry industry and is a trusted source of information for professionals. Subscriptions are free to qualified tube and pipe professionals in North America.